Non-mold method of forming objects and articles formed thereby

ABSTRACT

This invention relates to a non-mold method of forming articles and to the articles themselves wherein various configured articles may be fashioned with conformable material which may be easily fabricated as by sewing, or heat, or sonic welding to form the basic shape of or modular elements of a completed article, and wherein a thermal setting, flowable polymer or the like is introduced into the space between layers of the conformable material to thereby form the completed article or modular element.

RELATION TO OTHER APPLICATIONS

This is a continuation-in-part application of pending U.S. patentapplication in the name of the same inventor entitled NON-MOLD METHOD OFFORMING OBJECTS AND ARTICLES FORMED THEREBY, application Ser. No.09/195,596 having a filing date of Nov. 18, 1998.

BRIEF SUMMARY OF THE INVENTION

This invention relates to a non-mold method of forming articles and tothe articles themselves wherein various configured articles may befashioned with conformable material which may be easily fabricated as bysewing, or heat, or sonic or radio frequency welding to form the basicshape of or modular elements of a completed article, and wherein athermal setting, flowable plastic or the like is introduced into thespace between layers of the conformable material to thereby form thecompleted article or modular element thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the method of forming completed articles or inother instances, modular elements that will be assembled to form acompleted article.

The prior art has long recognized a method of forming articles using amolding process where expensive molds are machined and a thermal settingmaterial such as plastic or the like is injected into the mold, allowedto set and thereafter, the mold opened to remove a formed article whichthen requires, in most instances, some finishing before the article isready for marketing.

This methodology heretofore utilized has been expensive and timeconsuming, not only with respect to the initial expense of fabricatingthe mold, which requires highly skilled labor, but also with respect tothe manual labor needed in removing slashing, sanding, or otherwisefinishing the molded product to make the same, ready for sale. Theherein disclosed invention does away with the need of conventional moldsand the molding process in order to fabricate finished articles, whicharticles may be fashioned from conformable materials which are sewn orotherwise sealed together to form an inner space into which a flowable,thermal setting, resin or the like, is introduced so that the form ormold becomes part of the finished product itself. The overall saving inlabor, that is sewing and sonic or radio frequency, or heat welding,being much less than labor required in making molds and operating amolding machine, is readily apparent.

In addition, by making modular-type elements, the total of which makesup the whole of a finished article, individual elements of modularconstruction, employing designs and colors which would otherwise not beemployable, may be assembled in order to form desirable, marketableproducts.

2. Description of the Related Art

As far as is known, there is no prior art directly related to the hereindisclosed invention wherein a formed article is either modularlyfabricated and later assembled to complete the finished article, orwherein a non-molding process is utilized as contemplated in thecarrying out of the method of the invention.

However, the concept, in the broad sense of having inner and outer skinsor layers forming a space into which something is injected is relativelyold. Such items as inflatable pool toys and inflatable concrete bags forunderwater purposes are well known. But in the case of the inflatablepool toy, a fluid such as air is contemplated as opposed to a liquidsolid-forming polymer of this invention. Further, the pool toy form doesnot become part of a complete article, as contemplated in the instantinvention.

As regards to the underwater concrete bag, into which concrete isintroduced, the final shape, after setting of the concrete of theconcrete bag is determined by the ambient surroundings, such as seafloor, as opposed to the instant invention that utilizes a predeterminedshape and configuration for the patterns defining the ultimate shape ofthe completed article.

But, a prior search has been made and the most specific references foundare hereinafter enumerated, but none detract from the patentability ofthe disclosed invention and the articles formed thereby.

3,042,562—Product and Method for Production of Articles Having CompoundCurves—N. R. PETERSON

This reference is directed to a product and method for forming articleshaving compound curves without using a mold. The product can be foamedplastic having slits or grooves extending greater than halfway throughthe thickness of the sheet. A sheet 10 having slits 12 arranged to formadjacent columns 13 are on the top surface 17 and the bottom surface 18,with the slits staggered to be midway between those on one surfacerelative to those on the other surface. This slitting provides for acontinuous sheet that is very flexible. The sheet 10 is readily formedinto a wide variety of complex shapes. A shaped article 21 shown in FIG.7 is fabricated in accordance with this invention. The shaped article 21comprises a base shape 10 b having a plurality of slits 12 f and 12 g.The sheet is formed into a concave structure and the sheet and slits arefilled with a hardenable material 25. The entire article 21 is thencovered with a coating 26. The completed article 21 is rigid andself-supporting. A self-supporting object is made by applying ahardenable cement, grout, or filler material to the grooves or slitsopened by flexure of the sheet into a shape. The material upon hardeningprovides a permanent means for supporting the board in the formed shape.Articles such as boat hulls are readily fabricated by temporarilysupporting the slit sheets of polystyrene on a suitable form, coatingthe sheets with polyester resin woodflower mixture, or epoxy resinwoodflower mixture to fill the fissures and then applying a layer offibrous glass fabric to the outer surface. The slits in the sheet may bein a variety of patterns, as shown in FIGS. 2-5.

RE29, 394—Corrosion Protective Band for Underground Pipe Joints WithMetal Parts—Swanson, et al.

This reference is directed to impregnated foam bands for sealing belland spigot pipe joints. Reinforced concrete pipes 11, 12 having a steelbell ring 13 and steel spigot ring 14 are telescoped togethercompressing a rubber sealing gasket 17. Protection for the steel members13, 14 is provided by a pair of bands, a spigot band 21, and a bell band19. The bands are formed from a polyurethane foam impregnated withPortland cement and sealed for shipping and handling by a water solublemembrane 22. The spigot band 21 is stretched and pulled over the steelspigot ring 14. The bell band 19 is connected to pipe 11 by means of asuitable adhesive. On insertion of the spigot ring 14 into the bell ring13 of the next pipe, the outer and inner portions of the joint have thespigot band 21 and bell band 19 positioned respectively to protect thesteel bell and spigot rings 13, 14. Ground water contacts band 21 andthe Portland cement impregnated therein is hydrated. Similarly, thefluid in the pipeline activates the corrosion inhibiting properties ofbell band 19.

5,604,998—Sports Shoe Providing Heel Stabilization—Keijiro Kita

This reference is directed to a heel pad for a sports shoe formed ofopen cell foam impregnated with bouncing putty. A pad 8 ofthree-dimensional horseshoe shape may be formed from a stack of parts 12of polyurethane foam impregnated with bouncing putty. The pad may alsobe formed from a unitary block of polyurethane foam impregnated withbouncing putty and cut into the three dimensional horseshoe shape or athermoforming process may also be utilized. The pad may comprise abag-like sheet of synthetic resin 14 enclosing bouncing putty 13. FIG.11 shows a pad 8 comprising open cell foam 18 impregnated with bouncingputty 17. The pad 8 will have plastic deformation under heel pressure.It will be the same as the bouncing putty itself and exhibit bounceunder the impact force applied during athletic sports.

4,946,726—Orthopedic Splinting Articles and Methods Sandvig, et al

This reference is directed to an orthopedic splint of impregnated foamthat can be formed around a body part and hardened. The splintingarticle 10, a unitary blank, is a sheet of pliant foam initially formedas a rectangle for trimming to custom fit a patient. The foam sheet ofarticle 10 is open celled, impregnated by a curable resin. Beforeapplying article 10 to a patient, a cast padding 14 is preferably placedon the patient so as to prevent undesirable adhesion or contact betweenthe splint and the patient. The foam sheet is preferably impregnatedwith a water curable isocyanate functional polyurethane prepolymerresin.

5,002,047—Orthopedic Pads and Methods—Sandvig, et al.

This reference is directed to foam materials suitable for orthotic padsand methods of preparing the pads using the foam materials. A blank 10dimensioned as shown to be used as an orthotic foot pad is generallycomprised of a pliant extensible foam sheet of extensible foam that isopen-celled. The orthotic pad is impregnated with a solventless resinsystem and then sealed in a water vapor impermeable package which isopened just prior to use. In use, the package is opened and the blank isexposed to water. The patient's foot is positioned on the blank withpossibly using an appropriate interface barrier. The foot is held inplace with sufficient pressure to cause the surface of the pad toconform to the shape of the bottom of the foot and held until the pad issecured. The appropriate interface material can be a flexible stockinet14.

5,112,663—Method of Manufacturing Composite Structures Morenz, et al

This reference is directed to a method of making a composite structure,such as an aircraft wing, wherein sheets of flexible, open cell foam areimpregnated with a thermo-setting resin. A sheet of dry fiber reinforcedmaterial is placed on one or both sides of the impregnated foam sheet.The resulting sandwich is wrapped around a foam core and the assembly isplaced in a corresponding tool cavity. The tool cavity is heated to acuring temperature and the foam core expands into the confines of thetool.

5,338,024—Golf Club—Charles S. Baum

This reference is directed to a golf club head which is formed with aball impacting face having an outer layer of wood veneer bonded to aninner layer of synthetic resin reinforced fibers by a synthetic resinwhich impregnates both layers. The club head is formed by an outer shellbeing positioned over a molded foam plastic core, wherein the core iscovered with a flexible woven resin reinforced fiber sock and,thereafter the impregnation of the sock with an uncured synthetic resinis achieved and, thereafter the composite is cured in forming molds.

5,664,518—Composite Structures and Method of Making CompositeStructures—Lewit, et al

This appears to be a particularly pertinent patent in the sense that itdescribes making composite structures wherein a reinforcing fabric, suchas fiberglass is mechanically attached by stitching to a non-wovenpolyester fabric. The attached fabrics are placed in a mold withnon-woven fabric facing inside of the mold. A soft, expanding,self-curing foam is put into the mold, in an amount sufficient so thatupon expansion in a closed mold, the foam penetrates into theintricacies of the non-woven fabric, which upon curing forms a bondtherewith. However, note that a forming mold is required incontradistinction to the instant invention.

DISCLOSURE OF THE INVENTION

This invention relates to the method of forming composite objects orarticles comprising the combination of forming patterns of conformablematerial representative of the component sides of the final shape of theobject to be formed and affixing the formed patterns of conformablematerial along conforming lines to thereby form an intermediate spacetherebetween, after which a flowable polymer is introduced into theintermediate space. Thereafter, the flowable polymer is allowed topolymerize into a solid after which the formed object is producedwhereby the patterns of conformable material and said polymer areintegral.

In a more basic, general way, the invention is related to the non-moldmethod of forming a basic configuration of an article with at least aninner layer and an outer layer of conformable material to thereby forman intermediate space therebetween and introducing a solid formingmaterial into said intermediate space to thereby form a completedobject. The formed object may be of selected configuration and comprisesat least first and second secured layers of material, having anintermediate polymer solid therebetween, which comprises a modularelement in some instances or is capable of further additions to form acompleted object of desired shape and in other instances, may be thefinal object or article itself.

It is an important object of the invention to provide a method offorming objects not requiring molds in the conventional sense.

It is another important object of the invention to provide a method, andarticles formed thereby, wherein two layers of material are fashionedinto a desired shape by means of securement along their periphery bymeans of sewing or other bonding methods so that an intermediate spaceis formed and thereafter, filling said intermediate space with a thermalsetting polymer which after setting, forms an integral article ofdesired configuration and which may be used as a building block ormodular element to fashion a completed article.

It is still another more important object of the invention to have anon-mold forming process which does not rely on expensive machinery orlabor-intensive, high priced labor in order to form completed articles.

It is still another more important object of the invention to provide anon-mold forming process which does not require molds, expensivemachinery, or highly talented labor in order to fabricate or assemblefinished articles of desired shape and/or components.

It is another even more specific object of the invention to provide amethod of forming objects wherein the pattern or components themselvesused in forming the finished article or object becomes part, in anintegral manner, of the finished article or object itself.

It is still another more important object of the invention to provide amethod of forming modular elements using a non-mold forming processwherein menial labor is utilized for securing components together tothereby form finished articles of enhanced functional characteristics,but of relatively low-cost in terms of tools, jigs, molds, and labor.

It is still another more important object of the invention to provide anon-mold forming process wherein articles are fashioned from conformablematerial as by sewing, or heat, or sonic or radio frequency sealing sothat at least two layers of the material form an intermediate spacetherebetween into which is introduced, a flowable thermal settingpolymer which after setting up, forms the completed article itself orforms a basic modular element which may be easily assembled with othermodular elements to provide a finished, fabricated article.

These and other objects of the invention will become more apparent fromreferring to the hereinafter following commentary or specification takenin conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one type of article or object that ismade in accordance with the invention;

FIGS. 2, 3, 4, and 5 illustrate, in sequence, the methodology in oneembodiment of the invention in forming the article depicted in FIG. 1;

FIG. 6 is a view taken along the line 6—6 of FIG. 5;

FIG. 7 is a flow chart which schematically illustrates the generalmethodology of the invention;

FIG. 8 illustrates the top view of another embodiment of the inventionwherein individual components or modular units are utilized to make upthe finished article;

FIG. 9 is a side view of the article shown in FIG. 8;

FIG. 10 is a top view of another embodiment of the invention showing themodular concept of the methodology of the invention as applied to aspecific object such as a swim fin;

FIG. 11 is a schematic illustration of a different type of formedobject, in this case being a knee pad;

FIG. 12 schematically illustrates still another application of theinvention directed to a filter; and

FIG. 13 schematically illustrates the application of the invention to atennis racquet.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The detailed description set forth below in connection with the appendeddrawings is intended as a description of presently preferred embodimentsof the invention and is not intended to represent the only forms inwhich the present invention may be constructed and/or utilized. Thedescription sets forth the functions and the sequence of steps forconstructing and operating the invention in connection with theillustrated embodiments. However, it is to be understood that the sameor equivalent functions and sequence may be accomplished by differentembodiments that are also intended to be encompassed within the spiritand scope of the invention.

Before going specifically to the drawings illustrating several of themany embodiments contemplated to which the invention may be put, adescription of the starting materials would be appropriate.

Polymer

The type of polymer utilized in the practice of the invention will, asthose of ordinary skill in the art recognize, depend upon the finalproducts that are to be formed in the practice of the invention. In allinstances, a thermal setting plastic is contemplated and itscharacteristics chosen to more aptly suit the final needs of the productto be formed. That is, where the end product needs to be more flexible,a polymer will be chosen that has a durometer rating most compatiblewith the end result desired. In other instances where gravity flow, asopposed to pressure injection of the flowable polymer is contemplated,the viscosity of the polymer in the fluid state will become importantand those of ordinary skill in the polymer art and in deed, familiarwith the characteristics of the end products desired, will be able toreadily choose the polymers for the characteristics they possess andwhich are desired for the final formed product.

For example, with regard to a swimming fin of the type that will bediscussed hereinafter, a urethane polymer marketed by Uniroyal Chemicalunder the trademark VIBRATHANE, has been found to be suitable. Thecharacteristics of VIBRATHANE, designated by Uniroyal Chemical as B-625,has been found to be desirable with regard to its use in the swimmingfin used as one example for practicing the invention.

URETHANE PROPERTIES VIBRATHANE B-625 Prepolymer Property % NCO 6.09-6.56Amine equivalent 665 + 25 Appearance @ 75° F. (24° C.) Liquid TypicalViscosity @ 212° F. 170 (0.75) (100° C.), cps (pa-s) ProcessingInformation 1,4-butanediol level₁, pph 6.4 Vibracure 3095 level₁, pph —Curative temperature, ° F. (° C.) 140 (60) Vibrathane temperature, ° F.(° C.) 200 (93) Pot Life, Min.₂ 6 Urethane Properties Shore Hardness 85A100% Modulus, psi (MPa) 820 (5.6) 300% Modulus, psi (MPa) 1900 (13.1)Tensile, psi (MPa) 5400 (37.2) Elongation, % 460 Tear Strength (D470),pli (kN/m) 80 (14) Tear Strength, Die C, pli (kN/m) 540 (94.5) BashoreRebound, % 64 Compression Set, 22 Hrs./158° F. 29 (70° C.) Method B, %Bell Brittle Point, ° F. (° C.) <−80 (−63) Specific Gravity 1.09

While a specific polyurethane formulation is given, it is to beunderstood that other specific formulations may be utilized again,depending upon the end results desired and mere reference tomanufacturer's specifications similar to those given above, will allow aworker in the art to choose the polymer most suited to selectedapplications. For example, liquid polyvinyl chloride could be utilizedwith polyvinyl chloride or polyurethane sheet for the conformablematerial.

In some instances where a conformable material, as will be described, isused having a layer of plastic or polyurethane thereon, a polymer andcatalyst is chosen such that upon introduction and curing of thepolymer, the exothermic reaction causes introduced polymer and adjacentplastic or polyurethane layers on the conformable material to coalesceinto a single integrated mass.

Conformable Material

The type of material that lends itself most readily for the forming ofpatterns that are affixed to each other in a sealing relationship tothereby form an intermediate space to receive the flowable polymer maytake various forms, but generally will be a polyurethane, polyvinylchloride or other suitable plastic sheeting material or a fabric ofNylon, Kevlar, Hypalon and similar such polyester fabrics ranging indenier from 70 having 108×86 threads per inch to 200 denier having 40×40threads per inch. Again, a worker in the art will select and choose aconformable material or fabric depending upon the ultimate end use ofthe material for the finished article or modular element, keeping inmind the end use to which the same will be put. In some instances, wherea fabric is indicated, a courser or finer material will be dictated, aswill its being coated with different polymers to aid in the affixingprocess, especially where sonic welding is contemplated and even inthose instances where sewing or other affixing of the materials isemployed. In some instance, a mechanical bond between the pile of theconformable material and introduced flowable polymer will be desired andthus, the fabric chosen accordingly. Also, the mesh or scrim of thismaterial will aid in the bonding process between conformable materialand introduced polymer. Where plastic sheeting material is utilized, theflexibility or stiffness of the material will dictate its suitability ofuse in practice of the invention.

Several types of materials that have been found particularly useful forthe specific example of a swimming fin, as one of the describedembodiments of the invention, is URETEK 1115 put out by Uretek, Inc.,wherein the fabric is 70 denier nylon having 108×86 threads per inch andhaving a polyether polyurethane coating. Another suitable material putout by the same company under URETEK 2651 comprises a Kevlar type 29material of 200 denier with 40×40 threads per inch and having analiphatic polyether polyurethane coating. A suitable plastic sheetmaterial for use in swimming fins is a polyurethane sheet offered by J.P. Stevens Company under is designation MP1880. This sheet material is ageneral purpose, easily thermo-formable polyether polyurethane havingthe necessary degree of stiffness or flexibility for a wide range of enduses. Also, as previously stated PVC sheet material is also suitable.

Other materials that may be useful in the practice of the invention areoffered by Archer Rubber Company and more specifically by the CoatedFabric Group thereof, such materials are a basket weave Nylon understyle 9312 with a neoprene coating; style 2163 which is a polyesterfabric having a neoprene coating; style 9333 which is a polyester fabrichaving a neoprene coating; style 2141 which is a 420 denier nylon havinga hypalon/neoprene coating; and style 2085 which is 420 denier nylonhaving a neoprene coating and all such materials will be found to besatisfactory, depending upon the end uses to which the formed articlewill be put, keeping in mind that the material becomes part of thefinished product and thus, a worker in the art will select both materialand coatings depending upon color, sheen and other esthetic propertiesthat will be desirable to incorporate into the finished product.

Where a polyurethane sheet material is utilized for a swim finapplication, thicknesses in the range of about, by way of example andnot limitation,0.01-05 inch and a durometer of about 70-95A have beenfound useful. Obviously, other materials, thicknesses and pliabilitywill suggest themselves depending on the end uses to which theconformable material is to be put.

It is only important that the conformable material in most instances becapable of forming bonds with the introduced polymer, be easy to workwith in finishing the articles to be produced and be impermeable to theintroduced flowable polymer so same does not leak out.

Methods of Forming

The methods of forming articles of the invention are as prolific innumber as the imagination of a worker in the art permits. That is, withthe simplified mode of fabrication by taking a conformable materialwhether sheet or fabric, cutting out a pattern and affixing two layerstogether to form an intermediate space that is filled with a thermalsetting plastic, allows for a wide range of manufacturing techniques. Insome instances, an element of the assemblage comprising the finishedproduct may be mold formed, as with polyurethane foam, for integrationas by sewing, sonic welding or otherwise with modular elements that willmake up the remaining assemblage of the end product.

The totality of an article to be formed, where its configurationpermits, may be fashioned from the conformable material in sheet orfabric form or individual modular elements thereof may be made and thenaffixed together, depending upon the end results desired and as will beseen, fabrication methods permit the inclusion of padding,reinforcements or similar such additions. Again, all are dependent uponthe final end result to be attained.

Generally speaking, the invention contemplates a conformable fabricmaterial of the type having the characteristic previously describedwhich is easily cut to a configuration that the final article will take.In some instances, the two layers of conformable material or fabric areaffixed along their periphery either by sewing, RF welding, sonicwelding or other means, it only being important that an intermediatespace be formed between the two layers, whether these layers are coatedor uncoated, so that the flowable polymer may be introduced. In someinstances, in order to prevent ballooning or bulging out during thepolymer filling step, seams formed by sewing, RF welding, sonic weldingor otherwise may be utilized to limit the amount of intermediate spaceinto which the polymer is introduced.

The simplified method of formation readily lends itself for modularelement formation which elements are subsequently affixed, sewn orotherwise secured to each other to form a finished article of desiredshape, color and material characteristics.

Where sewing is contemplated, one need only utilize, depending upon thefabric or other material chosen, a heavy duty commercial-type sewingmachine in order to provide adequate seaming for both the periphery andintermediate areas of the patterns being formed. In other instances,heat welding by means of radio frequency techniques may be used in whichcase it becomes important to utilize a polymer coated material to allowfor the affixing of two layers of material along a periphery orintermediate section thereof, in order to provide the intermediatespaces into which the polymer is introduced.

Those of ordinary skill in the art will of course recognize other meansof formation of a configured article dependant upon the materialsselected and the end result desired.

Referring now to the drawings wherein like numerals of referencedesignate like elements throughout, there will be seen in FIG. 1, one ofthe exemplars of the practice of one embodiment of the invention. Hereindepicted, is an aquatic fin 2 having fin portion 4 and heel portion 6,intermediate of which are upstanding fastening portions 8 and 10 whichmay be secured around the foot of a wearer's foot by means of velcro,snaps, buckles or the like, not shown.

In the fabrication of the fin 2 shown in FIG. 1, two pieces of material1 and 3, like that heretofore described, are placed in position as shownin FIG. 2 either in side-by-side relationship or superimposed one on theother and a line pattern 5 drawn on each as shown in FIG. 3 in order toobtain two cut-out patterns 20 and 22 which are shown in FIG. 4 andwhich are superimposed on each other as shown in FIG. 5. The peripheryor outer edge 24 formed as by sewing, sonic welding or the like, createsa fixed boundary 26 about the periphery of the assemblage 28 with theexception of a small gap or orifice 30 through which flowable polymermay be introduced into the inner space 32 formed between layers 20 and22.

The assemblage 28, in addition to having the affixed perimeter 26, isprovided with a plurality of spaced seams 34 to form elongate channels36 into which polymer may be introduced.

Once the assemblage 28 has been sewn, fixed or sonic or radio frequencywelded, as heretofore described, polymer 38 such as one previouslydescribed is introduced into the opening 30 by means of gravity orpressure injection so as to fill the inner space 32 between the layers20 and 22 formed by reason of affixing of the perimetric edge 26 and theplacement of the seams 34. The formed polymer 38 is best seen in FIG. 6.

In its simplest form, the methodology of the practice of the inventionwith respect to obtaining the benefits of one embodiment heretoforedescribed is seen in the flow chart of FIG. 7.

There follows, by way of example and not limitation, a specific exampleof the formation of the fin 2 as shown in FIG. 1 as follows:

EXAMPLE

1. Two sheets of polyurethane-backed nylon cloth are cut according tothe fin pattern shape illustrated in FIGS. 2-4.

2. A sheet of nylon mesh is cut according to the same fin pattern shape.

3. The nylon mesh is positioned between two sheets ofpolyurethane-backed nylon cloth with the polyurethane backing on theinside (toward the mesh).

4. The three pieces are sewn together to form the shape of the fin andcavities as shown in FIG. 5. The edge cavities are sewn to form a cavityor inner space whose cross section starts at one inch at the foot pocketside of the blade and shrinks to one-half inch at the tip of the blade.The center cavity also narrows from one inch to one-half inch, but itonly extends half way from the foot pocket to the end of the blade. Thecavities extend to the heel of the foot pocket base to form an openingto pour thermoset polyurethane into. The opening extends a minimum oftwo inches from where the edge of the final product is to be.

5. Thermosetting polyurethane is poured into the heel-end opening andflows to the tip of the blade through the cavities. The initialtemperature of the polyurethane is 110° F.

6. The two-inch long excess length of the assembly is rolled ontoitself, forcing the polyurethane to fill any cavities not initiallyfilled. This is analogous to rolling the end of a tube of toothpaste,only the goal here is to fill the cavities, not empty them.

7. The thermosetting polyurethane system is formulated so that as itsets up, it exothermetically generates heat to a temperature above 275°F. This melts the polyurethane coating on the nylon cloth and binds itto the thermosetting polyurethane.

8. Once the thermosetting polyurethane sets up, the rolled end is cutoff, separate foot pocket buckles or straps are attached, and acompleted, non-mold formed fin is obtained.

Referring to FIGS. 8 and 9, there is shown still another embodiment ofthe invention, which in this particular case, is also directed to theformation of an aquatic fin 50. In the formation of aquatic fin 50,separate heel receiving portions 52 are formed which may be of formedpolyurethane foam and which may be fashioned in order to accommodate thehuman foot and more specifically, the contours and configuration thereofin both left and right configurations.

In the fabrication of fin 50, modular elements 54 and 56 are formedusing the methodology previously described with respect to fin 2.However, in this particular instance the modular elements 54 and 56 arein elongated form having the polymer introduced therein and whichelements are assembled, as by sewing or other affixing, to intermediateweb portions 58 which may be a singular layer of material such as semirigid polyurethane or a composite involving two layers affixed togetherhaving the polymer therebetween. A wide range of attractive colors maybe used for the various components to make an aesthetically pleasingdesign. Subsequently, a previously formed foot receiving portion 51 anda separate foam heel portion 52 is sewn or otherwise affixed to the twoelongate members 54 and 56 and thereafter, a strap or other affixingmeans, not shown, may be secured to the lateral sides of the footreceiving portion 51 by which the fin 50 may be securely fastened to theankle of a wearer of the fin 50.

In the construction of the fin 52 illustrated, various foam inserts forexample may be placed in the bottom of the heel portion 52 and in deed,separate foam elements may be fastened and secured into separateupstanding portions 8 and 10 as shown in FIG. 1 for fin 2. In otherwords, individual modular elements or components of the finishedarticle, in this case for example, fin 50 may be fabricated and easilyaffixed, one to the other as by sewing, bonding or other means wellknown in the art.

Referring now to FIG. 10, there is shown separate elongate members 70and 72 which are fashioned of a plurality of layers of materialspreviously described forming the inner space into which a polymer may beinjected or introduced and in this particular instance, the layers ofmaterial may have a plastic coating and the polymer used may beexothermic so that the heat generated melts the plastic layer to cause acoalescence or flowing of one material to the other in order to form anintegral mass or assemblage with respect to the thermal setting polymerand the layers of material.

In some instances, those of ordinary skill in the art will recognizethat a polymer layer may be desirable in order to ensure the integrationof polymer and layers of material as a unified assemblage or mass sothat the polymer once set will not move independent of the encapsulationwithin which it finds itself. In some instances, the mesh size orcoarseness of a fabric, for example, may ensure a mechanical attachmentor securement between the polymer and the fabric itself.

Those of ordinary skill in the art will recognize that the fin shown inFIG. 1 may have the upstanding portions 8 and 10 separately fashioned,as opposed to being integral as shown and described, and as previouslyalluded. In order to make a more comfortable fit with respect to thefoot and ankle of the wearer, there may be placed between the two layersof material a foam cushioning pad. The upstanding portions 8 and 10 maybe separately fabricated and later affixed to the remainder of the finarticle.

Other modifications will present themselves. For example in FIG. 10, thetwo elements 70 and 72 may be secured one to the other to fashion acompleted article such as a swim fin wherein elements 70 and 72 aresecured to each other by means of an intermediate web of flexible fabricor material such as previously described, in which event there would bea single layer as opposed to the dual layer forming the intermediate webspace therebetween in which case, no polymer would be injected.

Referring to FIG. 11, there is shown a knee pad 80 with elasticfastening members 82 to exemplify the type of objects that may be formedusing the methodology of the invention. Following the methodology of theinvention, the knee pad pattern is applied to two layers of fabric. Thelayers are affixed about their periphery and along selective cavities toallow the formation of an intermediate spaces therebetween andthereafter, the introduction of a thermal setting polymer in order toobtain, after solidification, a knee pad of a simple and practicaldesign, which is manufactured in an economical fashion. As those in theart will recognize appropriate sewing, sealing or sonic or radiofrequency welding will be desirable and necessary to form curves and toprevent ballooning or bulging.

There are a whole host of articles that may be fashioned utilizing thehereindisclosed invention wherein it is desired and desirable to havematerial which is utilized to fashion the article become a part of thearticle itself without the need of molds or a molding process.

For example, referring to FIGS. 12 and 13, an industrial type filter 84is illustrated wherein the outer frame 86 is formed by sewing togethertwo opposed pieces of fabric within which is secured screen or filtermember 88. Likewise, as shown in FIG. 13, a low cost, easilymanufactured tennis racquet 90 has the frame 92 formed as previouslydescribed for any article to be formed within which is secured gut ornylon strings 94.

While the present invention has been described with regards toparticular embodiments, it should be recognized that additionalvariations of the present invention may be devised without departingfrom the inventive concept and the appended claims are intended to coverall such embodiments.

I claim:
 1. A method of forming composite objects comprising thecombination of: a) forming two patterns of conformable materialrepresentative of a final shape of the object to be formed; b) sealingsaid two patterns together along the major periphery thereof to therebyform an intermediate space; c) introducing a flowable polymer into saidintermediate space and allowing said flowable polymer to polymerize intoa solid; said two sealed patterns unsupportedly providing said finalshape of said object. d) obtaining the formed object whereby saidconformable material and solid polymer are integral.
 2. The method inaccordance with claim 1 wherein said conformable material comprises asynthetic fabric having a mesh surface on at least one surface thereoffacing interiorally of said intermediate space so as to be able to formattachment means for the flowable polymer.
 3. The method in accordancewith claim 1 wherein at least one of said two patterns has a polymercoating.
 4. The method in accordance with claim 3 which includes a webof material within said intermediate space whereby securement of polymerand opposed two patterns of conformable material is obtained.
 5. Themethod in accordance with claim 3 wherein said polymer polymerizesexothermically.
 6. The method in accordance with claim 4 wherein saidweb is a polymer and securement is obtained from the exothermic heat ofpolymerization.
 7. The method in accordance with claim 5 wherein saidpolymer is chosen to exothermically generate sufficient heat to causemelting of said polymer coating such that coalescence of said flowablepolymer and polymer is obtained to form an integral mass.
 8. The methodin accordance with claim 1 wherein said conformable material comprises afabric having a sufficiently thick pile on at least one surface thereoffacing interiorally of said intermediate space so as to allow themechanical attachment between conformable material and polymerizedflowable polymer.
 9. The method in accordance with claim 1 where saidconformable material comprises a material selected from polyurethane andpolyvinyl chloride sheets.
 10. A method of forming a modular compositeobject comprising the combination of forming two layers of conformablematerial representative of the modular shape of the element to beformed; sealing the two layers along a major periphery thereof tothereby form an intermediate chamber; introducing a thermal settingflowable polymer into said chamber and allowing said flowable polymer topolymerize into a solid; said two sealed layers unsupportedly providingsaid modular shape of said element and obtaining the formed modularelement whereby the layers of material and said polymer are integralwith the outer surface of said conformable material which forms a partof the modular element itself.